COMPOSITE INDUSTRIAL WINDING CORE AND METHODS

Abstract

A high performance and lightweight composite industrial winding core for winding a thin material stock thereon. In preferred embodiments, the winding core is engineered from fiber reinforced plastic and comprises a pair of elongate winding core bodies aligned along an axis having a generally cylindrical outer face with an inner face that defines the inside of the hollow cylinder. A first end wall and a second end wall enclose the ends of the winding core. A series of spaced axle supports support the winding core bodies. An inner axle face engages with an axle shaft. Portions of the winding core can be joined by an adhesive resin or bonding agent. The axle shaft can include inflatable bladders and can engage an inner tube of the winding core. A method for using a winding core to wind material stock is disclosed.

Description

BACKGROUND OF THE INVENTION

Field of the Invention The invention relates generally to winding cores for winding a thin material stock thereon, and more particularly to high performance light weight winding cores.

Description of Related Art Winding cores noted in the prior art to date have been manufactured using either paper or fiberglass laminated with phenolic resin. These prior art winding cores are typically continuous tubes with bonded and pinned ends.

What is needed are light weight, strong, and durable winding cores that are inexpensive and otherwise high performance. What is needed are winding cores that are smartly engineered to meet and exceed these demands.

SUMMARY OF THE INVENTION

Disclosed herein are novel winding cores of various sizes and shapes which are characterized by their reduced weight, strength, durability, and ability to be rapidly manufactured.

In one form, in a method of use of a composite winding core, a shaft with an expandable bladder is inserted through the center bore of the winding core. The bladders are expanded and consequently secure the shaft to the bore. The shaft is then turned to take up a variable amount of foil, film, or other material on the outer cylindrical surface of the core. The coil of this material stock is then transported and stored as needed.

In one form, the method of manufacture and design can be effectively used by substituting any number of combinations of resins and/or reinforcements.

In one form, winding cores as disclosed herein have the advantage of being lighter in weight, more easily manufacturable, and more quickly manufactured than existing technologies.

In one form, a winding core comprises a pair of elongate winding core bodies aligned and joined along an axis.

In one form, engineered FRP (fiber reinforced plastic) materials are used to fabricate the winding core.

In one form, the winding cores abut at mid face of each winding core body.

In one form, the winding core bodies comprise an outer radial wall distanced from and encircling the central axis of the winding core.

In one form, an outer face of the outer radial wall is generally cylindrical, whereas the inner face defines the inside of the substantially hollow cylinder.

In one form, the inner face can be sloped or otherwise comprise a draft defining an inner space.

In one form, the outer radial wall can be of a constant thickness, or a variable thickness.

In one form, an inner space of the winding core has a wider diameter near the mid face. and a smaller diameter approaching the end walls.

In one form, spanning across the junction of the mid faces of the opposed winding core bodies is an inner axle support that is securely bonded to the inner faces of the outer radial walls.

In one form, a winding core has a first end wall partially enclosing a first end, and a second end wall partially enclosing a second end.

In one form, a first outer end face is on the first end wall and a second outer end face is on the second end wall and face outward.

In one form, a first inner end face on the first end wall and a second inner end face on the second end wall face inward towards an inner space.

In one form, the first end wall and second end wall are substantially planar and positioned substantially perpendicular to the central axis (axis A). In other forms, these end walls can assume other profiles besides planar without loss of function.

In one form, a substantially cylindrical inner radial wall extends a distance sufficient to support an axle towards the inner space from both the first end wall and second end wall.

In one form, an inner axle support comprises a substantially cylindrical inner radial wall that is encircled by a spanning wall that extends between the inner radial wall and outward radial wall of the inner axle support.

In one form, the spanning wall is in a plane perpendicular to axis A. In alternative configurations, the spanning wall can be angled or curved.

In one form, an inner axle face is formed on the inner radial walls and defines part of an aligned axle cavity through the winding core for seating and supporting an axle therein.

In one form, an end axle face terminates each segment of the axle seats. The end axle faces spans between the inner axle face and outer axle face formed on the outer facing aspect of the inner radial walls.

In one form, an adhesive resin or bonding agent such as epoxy is used during manufacture to secure the outer radial face of the inner axle support to the inner face of the outer radial wall.

In one form, the inner axle support is positioned whereby the outer radial face overlaps the inner face of both of the opposing winding core bodies where they are joined at their mid faces. This forms a strong and rigid winding core.

In one form, a first inner tube extends between the inner axle support and the first end axle support.

In one form, a second inner tube extends between the inner axle support and the second end axle support.

In one form, the inner tubes comprise an interior face defining the inside of the inner tube and configured to house an inflatable axle, an outward face defining the outside of the inner tube, and a terminal face defining terminal ends of the inner tube. In some embodiments, the terminal face comprises an interlock flange for interlocking with the inner radial wall of the respective first end axle support or second end axle support.

In one form, the interlock flange is in the form of a circumferential rim.

In one form, the inner axle support is symmetrically formed about a spanning wall although non-symmetrical profiles can be used.

In one form, the first end axle support and second end axle support comprise a plurality of radially positioned axle ribs to provide strength and rigidity through two or more junctions of the axle ribs with the respective end wall, inner radial wall, and outer radial wall.

In one form, an expandable axle is utilized in conjunction with a winding core and fits in an axle cavity of the winding core.

In one form, the expandable axle is available for purchase as a common off the shelf good.

In one form, the expandable axle comprises a generally cylindrical axle shaft with an axle surface defining the outer surface of the shaft. The axle shaft is supported, and forces to rotate the shaft are introduced near the ends of the shaft.

In one form, inset from the ends of the shaft are one or more bladders. The bladders have a bladder surface defining the outside of the bladder.

In one form, an inflation channel with valve extends through the expandable axle to the inside of the bladder where liquids or gases can be introduced to cause inflation of the bladder(s).

In one form, the expandable axle is supported by anchored bearings at each end of the expandable axle.

In one form, steps in a method in one embodiment for using a winding core to wind material stock is as follows. Obtain a winding core. Obtain an axle with expandable bladder sized to fit within an axle cavity of the winding core. Seat the axle with expandable bladder within the axle cavity of the winding core in a deflated state. Introduce air/fluid into the expandable bladder thereby securing the axle shaft within the axle cavity. Secure an end of a material stock (i.e. foil or film) to the winding core. Introduce a rotary force on the axle with an expandible bladder to wind a desired amount of material stock on the winding core. Deflate the bladder and remove the axle from the winding core if desired. Transport and store the spool of foil or film at a desired location.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein each drawing is according to one or more embodiments shown and described herein, and wherein:

FIG. 1 depicts a top perspective view of a winding core;

FIG. 2 depicts a top perspective cross-sectional view through plane B of the winding core of FIG. 1 with inner tubes removed;

FIG. 2A depicts a top perspective cross-sectional view through plane B of the winding core of FIG. 1 with inner tubes in place;

FIG. 3 depicts a top perspective cross-sectional view through plane C of an axle support;

FIG. 4 depicts an inside end view of the axle support of FIG. 3;

FIG. 5 depicts a cross-sectional view of the winding core of FIG. 1 along plane D;

FIG. 6 depicts a top perspective view of an axle support used in the winding core of FIG. 1;

FIG. 7 depicts a top perspective cross-sectional view through plane D of the winding core of FIG. 1;

FIG. 8 depicts a top perspective view of an expandable axle having bladders;

FIG. 9 depicts a cross-sectional view through plane B of a winding core with axle and bladders;

FIG. 10 depicts a top perspective view of a winding core with expandable axle in an exploded configuration;

FIG. 11 depicts a top perspective view of the winding core with expandable axle in an operational configuration;

FIG. 12 depicts a top perspective cross-sectional view through plane B of a winding core with inner tubes removed;

FIG. 13 depicts a top perspective view of a winding core with expandable axle and with material stock thereon;

FIG. 14 depicts a top perspective view of the winding core and expandable axle with the beginning of the material stock unwinding from the bundle;

FIG. 15 depicts a graphic showing a method of using a winding core.

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS OF THE INVENTION

Select embodiments of the invention will now be described with reference to the Figures. Like numerals indicate like or corresponding elements throughout the several views. The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive way, simply because it is being utilized in conjunction with detailed description of certain specific embodiments of the invention. Furthermore, embodiments of the invention may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the invention described herein.

FIG. 1 depicts a preferred embodiment of a novel winding core 100. The winding core comprises a pair of winding core bodies 102 aligned along axis A and abutting at mid face 109 of each winding core body 102. FIG. 2 depicts a cross-sectional view of winding core 100 (first inner tube 170 and second inner tube 172 removed) through plane B that is aligned with axis A. FIG. 2A depicts a cross-sectional view of winding core 100 with first inner tube 170 and second inner tube 172 in place. The winding core bodies 102 comprise an outer radial wall 104 distanced from and encircling axis A. An outer face 108 of the radial wall 104 is generally cylindrical, whereas inner face 106 defines the inside of the cylinder. In this embodiment, radial wall 104 can be of a constant thickness, or as depicted having a variable thickness/drafted internally, wherein for example, the wall is thinner at T2 compared to T1. In this case, the inner space 105 has a wider diameter near opposed mid faces 109 and a smaller diameter approaching the end walls (first end wall 110 and second end wall 112). Spanning across the junction of the mid faces 109 of the opposed winding core bodies 102 is an inner axle support 140 that is securely bonded to the inner faces 106 of the outer radial walls 104. When assembled, winding core 100 has a first end wall 110 partially enclosing a first end, and a second end wall 112 partially enclosing a second end. A first outer end face 114 on the first end wall 110 and a second outer end face 118 on the second end wall 112 face outward whereas, a first inner end face 116 on the first end wall 110 and a second inner end face 120 on the second end wall 112 face inward towards inner space 105. In this embodiment, the first end wall 110 and second end wall 112 are substantially planar and positioned substantially perpendicular to the central axis (axis A), however in other embodiments, these end walls can assume other profiles other than planar.

A substantially cylindrical inner radial wall 122 extends a distance sufficient to support an axle towards inner space 105 from both the first end wall 110 and second end wall 112. In addition, inner axle support 140 also comprises a substantially cylindrical inner radial wall 122 that is encircled by a spanning wall 121 that extends between the inner radial wall 122 and outward radial wall 123 of inner axle support 140. The spanning wall in this embodiment, like the first and second end walls are substantially in a plane perpendicular to axis A, however, other variations other than perpendicular can also function well. An inner axle face 124 is formed on the inner radial walls 122 and defines an aligned axle cavity 168 through the winding core 100 for seating an axle therein. An end axle face 125 terminates each segment of the axle seats 119. The end axle faces spans between inner axle face 124 and outer axle face 126 formed on the outer facing aspect of the inner radial walls 122.

As noted in FIG. 2A, a first inner tube 170 extends between the inner axle support 140 and the first end axle support 142. In some embodiments, the first inner tube and second inner tube are manufactured from a fiberglass and are substantially cylindrical. A second inner tube 172 extends between the inner axle support 140 and the second end axle support 144. The inner tubes comprise an interior face 178 defining the cylindrical inside of the inner tube, an outward face 180 defining the outside of the inner tube, a central face 174 defining the central facing end, and a terminal face 176 defining terminal ends of the inner tube. In some embodiments, the terminal face 176 comprises an interlock flange 182 for interlocking with the inner radial wall 122. In some embodiments, the interlock flange is in the form of a circumferential rim or step. In preferred embodiments, the individual components making up winding core 100 (FIG. 2A) are bonded together to form a single integral unit.

FIG. 5 is a cross-sectional end view of winding core 100 through plane D (inner tube removed), whereas FIG. 7 is a perspective view through plane D (inner tube removed). FIG. 6 is a perspective view of inner axle support 140. As noted in FIG. 7, a bonding agent 146 (i.e. epoxy) is used during manufacture to secure outer radial face 127 of inner axle support 140 to inner face 106 of outer radial wall 104. As noted in at least FIG. 2, inner axle support 140 is positioned whereby radial face 127 overlaps inner face 106 of both of the opposing winding core bodies 102 where they are joined at their mid faces 109 to form a strong and rigid winding core. In this embodiment, inner axle support 140 is symmetrically formed about spanning wall 121 although non-symmetrical profiles can be used. As noted earlier, inner face 106 can be drafted and similarly outer radial face 127 of inner axle support 140 can also be drafted to produce complementary surfaces.

FIG. 3 is a cross-sectional perspective view through plane C (inner tube removed), whereas FIG. 4 depicts a cross-sectional end view through plane C. As noted in at least FIGS. 2-4, the first end axle support 142 and second end axle support 144 can comprise a plurality of radially positioned axle ribs (i.e. first axle rib 128, second axle rib 130, third axle rib 132, fourth axle rib 134, fifth axle rib 136, sixth axle rib 138) to provide strength and rigidity through junctions of the axle ribs with the respective end wall (first end wall 110, second end wall 112), inner radial wall 122, and outer radial wall 104.

FIG. 8 depicts a view of an expandable axle 158 having axis B that can be utilized in conjunction with the winding core 100 when centered within axle cavity 168 of the winding core. The expandable axle 158 comprises a generally cylindrical axle shaft 160 with an axle surface 162 defining the outer surface of the shaft. The axle shaft is supported with supports such as anchored bearings 184, and rotary forces 184 to rotate the shaft are introduced, near the ends of the shaft. The axle shaft in some embodiments is hollow. Inset from the ends of the shaft are one or more bladders 164. The bladders have bladder surface 166 defining the outside of the bladder. An inflation channel with valve 165 extends to the inside of the bladder. FIG. 8 depicts the bladder 164 in a deflated state. The bladders will enlarge in outer diameter due to introduction of liquids or gases into the bladder through the valve and inflation channel. The bladders are contained in the axle shaft which is inserted into axle cavity 168. The bladders are inflated against the walls of the axle shaft 160 in order to transfer torque to the winding core to provide tension during uptake of material stock and to provide braking during unwinding of the material stock. FIG. 9 is a cross-sectional view of winding core 100. FIG. 10 depicts an expandable axle 158 aligned with a winding core 100, whereas FIG. 11 depicts the winding core seated within the axle cavity 168. FIG. 12 is a cross-sectional view of FIG. 11 with inner tubes removed. FIG. 13 depicts a winding core 100 on an expandable axle 158 with material layers 152 of a material stock 150 thereon. FIG. 14 depicts the material stock beginning 156.

FIG. 15 depicts one embodiment of steps in a method for using a winding core 100 such as embodiments of winding cores described within the specification. The steps in the method are as follows. Obtain a winding core 100 as disclosed herein (200). Obtain an expandable axle 158 having axle 160 with expandable bladder 164 sized to fit within an axle cavity 168 of the winding core (202). Seat the axle 160 with expandable bladder 164 within the axle cavity 168 of the winding core 100 (204) as depicted in FIG. 11. Introduce air/fluid into the expandable bladder thereby securing the expandable axle within the axle cavity due to the friction between bladder surface 166 and inner axle face 124 and interior face 178 (206). Secure a material stock end 154 of a material stock 150 (i.e. foil or film) to the winding core 100 (208). Introduce a rotary force on the axle surface of the expandible axle to wind a desired amount of foil or film on winding core (210) until reaching the material stock beginning 156 thereby creating a plurality of material layers 152 on the winding core. Deflate the bladder and remove the axle from the winding core if desired (212). Transport and store the spool of foil or film at a desired location (214).

It is noted that the terms “substantially” and “about” and “generally” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention.

Claims

1. A winding core comprising: a winding core body having a central axis;said winding core body comprising an outer radial wall;said outer radial wall having outward facing outer face defining a cylinder;said outer radial wall having an inward facing inner face defining an internal cylinder;an end wall enclosing a first end of said winding core body;an inner radial wall extending from said end wall into said internal cylinder;said inner radial wall having an inner axle face defining an axle cavity operable for seating an axle therein; and,said inner radial wall having an outer axle face spaced inward from said inner face.

2. The winding core of claim 1 wherein said outer radial wall is thickens as it approaches said end wall.

3. The winding core of claim 1 wherein said outer radial wall thickness is substantially constant.

4. The winding core of claim 1 further comprising: a plurality of axle ribs extending between said outer axle face and said inner face thereby securing said inner radial wall concentric to said outer radial wall.

5. The winding core of claim 4 wherein said plurality of axle ribs are equally spaced to each other.

6. The winding core of claim 4 wherein said plurality of axle ribs are also integral with an inner end face.

7. The winding core of claim 1 further comprising: a central face;said central face extending between said outer face and said inner face; and,wherein said central face is substantially perpendicular to said central axis.

8. The winding core of claim 7 further comprising: a second winding core body;wherein said first winding core body and said second winding core body are aligned along said central axis; and,wherein said central faces of each winding core body abut each other.

9. The winding core of claim 8 further comprising: an inner axle support;said inner axle support comprising a substantially cylindrical outward radial wall;said outward radial wall sized to fit within said inner space of said winding core body;an inner radial wall with inner axial face thereon forming a cylinder operable to house an axle;a spanning wall spanning between said outward radial wall and said inner radial wall of said inner axle support thereby concentrically securing the position of said outward radial wall in relation to said inner radial wall along said central axis.

10. The winding core of claim 9 wherein said inner axle support is positioned within said inner spaces overlapping said winding core bodies and bonded in position.

11. The winding core of claim 10 further comprising: at least one inner tube;said inner tube comprising a cylindrical inner tube wall;said inner tube wall comprising an outward face facing outward;said inner tube wall comprising an interior face facing inward;said interior face defining an axial cavity for housing said axle; and,wherein said at least one inner tube extends between said end axle support and said inner axle support and is aligned with said central axis.

12. The winding core of claim 11 further comprising: an interlock flange at an interior end of said inner radial wall; and,wherein said interlock flange is configured to interlock with said inner tube.

13. The winding core of claim 1 further comprising: an axle;wherein said axle is seated within said axle cavities.

14. The winding core of claim 9 further comprising an expandable axle.

15. The winding core of claim 14 wherein said expandable axle comprises one or more bladders operable to expand and drive said winding core bodies.

16. The winding core of claim 15 wherein said expandable axle further comprises an inflation channel; and, wherein said inflation channel is utilized to introduce fluid into said one or more bladders for inflation.

17. The winding core of claim 16 wherein inflation of said one or more bladders reduces slippage between said axle and said winding core bodies.

18. The winding core of claim 1 wherein said winding core body is manufactured from a fiber reinforced plastic.

19. A method of using a winding core comprising the steps of: obtaining a winding core;obtaining an axle with expandable bladder sized to fit within the axle cavity of the winding core;seating the axle with expandable bladder within the axle cavity;introducing a fluid such as air into the expandable bladder securing the expandable axle within the axle cavity;securing an end of material stock to the winding core; and,introducing a rotary force on the axle thereby winding the material stock on the winding core.

20. The method of claim 19 further comprising the step of; deflating the bladder and removing the axle and bladder from the winding core.